10/1.5.1 Rev. 0
CONTROL VALVES
SINGLE PORTED CLASSES DL, DDL, DOS, DDOS TABLE OF CONTENTS
INSTALLATION ..............................................................................................................................2
VALVE POSITION .........................................................................................................................................2 PROBLEM PREVENTING PROCEDURES ..........................................................................................................2
NOTE 1: Where noise is a factor follows recommendations for piping and fittings per 5/0.3.1.
Illustration Index
Figure 1 - Typical Installation .........................................................................................................................3 Figure 2 - Typical Control Valve Station for Control of Compressible Fluids at 25% or Less of Inlet Pressure .................................................................................................................................................................3 Figure 3 - Cage Trim (DOS Type) ..................................................................................................................5 Figure 4 - Single Ported Control Valve Body Assmebly (Actuator Removed)...............................................5 Figure 5 - Use of Seat Ring Wrenches to Remove or Install Seat Rings.........................................................6 Figure 6 - Main Body Sub-Assembly..............................................................................................................6 Figure 7 - Alternate Method ............................................................................................................................7 Figure 8 - Direct Acting Diaphragm Actuator...............................................................................................10 Figure 9-Reverse Acting Diaphragm Actuator..............................................................................................10
bonnet or paint it other than dull black, otherwise its heat emitting efficiency will be impaired and packing will be submitted to excessive temperature. CAUTION! The piping system must be adequately designed and supported to prevent extraordinary loads to the pressure RECOMMENDED PIPING FOR CONTROL OF COMPRESSIBLE FLUIDS AT VALUES OF 25% OR LESS OF INLET PRESSURE. 1. Expand outlet pipe to twice control valve inlet pipe size. Use tapered expander. Connect control pipe for control pilot ahead of outlet stop valve and at least 2 to 3 downstream from end of expander. Make control pipe connection at least 18 to 24 from outlet stop valve, any elbow or other flow direction out changing fitting. (see Fig. 2)
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NOTE: Where sensing impulse is taken 2 to 3 downstream from control valve (expander), dimension A minimum of 6 to 10 will provide lowest noise and velocity factors, accurate pressure sensing and reasonable bypass length.
Connect operating medium tubing from control pilot instrument or loading device to diaphragm chamber connection of control valve or to valve positioner, if one is in use. Important: If control valve is fitted with a Thermo-Isolating bonnet, do not lag or insulate
OPERATION
1. 2. Close inlet and outlet stop valves. Check that control valve responds properly through rated travel in relation to changes in operating pressure on the
diaphragm. Rated travel is shown by position of travel indicator on valve stem relative to travel indicator scale on yoke. 3. Manually operate control valves fitted with manual operating devices through rated travel to check freedom of movement. Place control valve in operation in accordance with instructions furnished with control pilot or other operating device.
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MAINTENANCE
(DL, DDL, DOS, DDOS 600 lbs. or less)
NOTE: To reduce maintenance time refer to proper drawing and follow steps shown below for applicable maintenance operation. To Renew Valve Plug Stem Packing To dismantle Control Valve Inspect Parts Replace or Regrind Valve Plug/Seat Ring(s) To Reassemble Control Valve To Preload Adjusting Spring Set Rated Travel To Replace Diaphragm and/or Stem Seal To change Valve Action Normally Open to Normally Closed or Vice Versa Maintenance Maintenance Dismantling -
Dismantling
1. Close inlet and outlet stop valves. Operate system on bypass, if necessary. Shut off operating medium and relieve pressure from diaphragm by disconnecting tubing at diaphragm case.
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WARNING Injury or death can occur due to failure to completely isolate valve from all sources of pressure before beginning disassembly. Do not proceed until valve has been completely isolated from the process and vented to atmosphere.
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Single Ported Unbalanced Types DL, DOS Types (See Fig. 3 and 4)
Remove nut (29) from valve plug stem. Disassemble bonnet bolts/nuts (45/42). Lift bonnet, valve plug assembly and bonnet gasket (44) off valve body. Loosen and remove bottom cap (flange) (48) and gasket (47) where applicable. Disassemble packing flange bolts/studs (37), packing flange (36) and packing follower (38) from bonnet. Clean out packing box.
All Leslie control valves are made of the finest material obtainable, time-tested and backed by over 100 years of know-how. Machining is done by an expert craftsmen and each valve is inspected and service tested before shipment to you. Use of other than genuine Leslie parts may impair their ability to serve you. Leslie parts are held to very close tolerance to eliminate field machining and grinding on valve and seat ring/inserts or reaming on (valve plug guide bushings).
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Ordering Parts
Order parts from the proper drawing. Give valve type, size, press class and part(s) reference number(s) or part name, valve code number and serial number.
Cleaning
Figure 6 - Main Body Sub-Assembly Clean all parts thoroughly with an approved, non-residue forming solvent. Remove encrusted material with crocus cloth or very mild aluminum oxide cloth. For parts repair information, consult your local Leslie Representative. 1. Bonnet acts as guide when grinding valve plug. Loosen packing flange studs/bolts slightly if packing is installed. Uses wrench on flats of valve plug stem for turning valve plug. Do not bear down on
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valve plug stem when lapping. Weight of parts is sufficient to cause lapping action. 4. 5. Place lapping compound on valve plug face. As lapping progresses lift valve plug off seat occasionally and rotate 45 to keep compound evenly distributed. Remove all traces of compound after lapping.
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10. Reassemble nut (34) and travel indicator (31) to valve plug stem. 11. Lift valve plug stem and engage its threads with those in actuator stem (25). 12. Screw valve plug stem at least one diameter into actuator stem. 13. Adjust actuator spring preload and rated travel of valve. (See Adjusting Actuator Spring Preload).
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Place new gasket (50) in recess in valve body. Follow with seat ring/insert (51), with valve plug seating face toward bonnet end of body. Position seat retaining guide (48) on seat ring/insert.
spring must be sufficient to provide the 3 psig preload plug force required to close the valve. If preload adjustment is made with no pressure in valve body, when the control valve is placed in operation, additional compression must be placed on the actuator spring to provide valve closure force. With proper adjustment valve will close tightly and will not begin to open until the 3 psig operation pressure is exceeded. NOTE A: A control valve which has been adjusted to provide 3 psig starting pressure plug valve closure force (with pressure in body) will have a considerably higher start-pressure than 3 psig, when tested at 0 body pressure. NOTE B: Air pressure quoted are relative. Actual pressures required in operation may vary with pressure drop conditions existing and/or actuator springs used.
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TO COMPRESS ACTUATOR SPRING SCREW SPRING ADJUSTOR UPWARD NOTE: Alternately add compression and check starting pressure slightly above 3 psig until correct adjustment is attained. After each check, return air pressure to 3 psig.
plug away from seat ring/insert(s). Then turn valve plug stem one full turn out of actuator stem threads until valve plug just contacts seat ring/insert again.
Reassembly
Replace internal parts. Install new diaphragm. For sizes 35, 55 and 85 line up holes with those in lower diaphragm case. For size 135 place bead on diaphragm in recess in lower diaphragm case. Place upper diaphragm case on diaphragm. Assemble four bolts and nuts through parts (90 apart). Finger tighten. Assemble balance of bolts/nuts to actuator. Tighten evenly and alternately across diaphragm case. (Before tightening bolts in 35R actuator or where flat diaphragm material is being used as an emergency measure) consult note relating to preforming diaphragms. Reverse Acting (See Page 9, Valve Action) Remove bolts/nuts (19/18) and upper diaphragm case (15). Insert rod through holes in yoke (34) and actuator stem (35) to prevent twisting of stem seal (29) when removing self-locking nut (16). (For size 35R use wrench flats on actuator stem). Remove self-locking nut (16), diaphragm plate (17), diaphragm (20), collar (22) and stem seal (29). Remove stem seal as follows: (Before tightening bolts in 35R Actuator or where flat diaphragm material is being used as an emergency measure). In 135R remove capscrews (23) in 35R and disassemble lower diaphragm base (21) from yoke (34). Lift out stem seal. In 55R and 85R DO NOT remove lower diaphragm base unless gasket (26) needs to be replaced. Stem seal (29) is held in place by seal ring (27) and screws (28). Remove these parts and lift out stem seal.
Tighten stem locknut and travel indicator against actuator stem. Reconnect operating medium tubing from the sensing element or manual loading device to the diaphragm case.
Reassemble spring adjuster (40), washer (39), actuator spring (36), top spring seat (30) to actuator stem (35) (If they have been removed). Replace assembled parts in yoke (34). Place stem seal collar (31) on actuator stem (35). Reassemble spacer (33) to yoke in 135R. Position stem seal collar (31) on actuator stem (35). In sizes 55R, 85R and 135R place bead of stem seal in recess of stem seal collar. In 35R and 135R actuators reassemble lower diaphragm base (21) to yoke (34). Assemble nuts (24) to spacer studs (32) in 135R. Tighten. In 35R insert capscrews (23) through holes in lower diaphragm case and diaphragm and into threads in yoke. Tighten after presetting stem seal as described below. In 55R and 85R actuators replace sealing ring (27) and screws (28). Tighten. Presetting Stem Seal (55R, 85R & 135R) Place collar (22) on stem seal (29) making sure that bead on stem seal enters recess in collar. Reassemble diaphragm (20) over actuator stem (35). Fit center hole in diaphragm around raised face of collar (22). Replace diaphragm plate (17) and self-locking nut (16). Hold actuator stem steady with rod through yoke and stem (55R, 85R, 135R) or with wrench on flats on actuator stem (35R) then tighten self-locking nut. Replace upper diaphragm case (15) and bolts/nuts. Tighten as described previously. See Instruction Sheet 10/0.5.8 for precautions to observe when replacing seals.
Presetting Stem Seal (135R) Place collar (22) on stem seal (29), assemble self-locking nut (16) to actuator stem (35) and tighten down against parts. Then press actuator stem downward to make stem seal move to taut position. Tighten capscrews and remove selflocking nut (16).
Figure 9-Reverse Acting Diaphragm Actuator NOTE: To check actuator spring and other components in size 135R disassemble spacer (33) and lift out parts. In 35R, 55R and 85R parts are taken out from the underside.
All Actuators
Set preload on actuator spring, reassemble actuator to valve body assembly, if it has been removed, adjust valve for rated travel and reconnect operating medium tubing.
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SOME IMPORTANT NOTES FLAT SHEET RUBBER MATERIAL Flat sheet rubber material may be used in 55R, 85R and 135R actuators as emergency replacement material but for guaranteed results it should be replaced at the earliest opportunity with the LESLIE ROLLING ACTION DIAPHRAGM designed specifically for these actuators. When flat material is used in emergency preform as described below. PREFORMING 35R ACTUATOR DIAPHRAGMS Flat stock material is used for diaphragms in 35R actuators. When assembling, first finger tighten all diaphragm case bolts. Then compress actuator spring sufficiently to move diaphragm through full travel to the upper or lower diaphragm case (depending on whether actuator is direct or reverse acting). This preforms diaphragm and permits full movement through rated travel without resistance from a taut diaphragm.
travel. For more detailed instruction consult general instruction pertaining to the particular type of control valve.
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It is solely responsibility of system designer and user to select products and materials suitable for their specific application requirements and to ensure proper installation, operation and maintenance of these products. Assistance shall be afforded with selection of materials based on technical information supplied to Leslie Controls Inc.; however, system designer and user retain final responsibility. Designer should consider applicable Codes, material compatibility, product ratings and application details in selection and application. Improper selection, application or use of products described herein can cause personal injury or property damage. If designer or user intends to use product for an application or use other than originally specified, he must reconfirm tat selection is suitable for new operating conditions. Life expectancy for this product defaults to warranty period of sales contract. 12